2006 530xi AC clutch-pulley removal help, please. - Bimmerfest - BMW Forums



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E60 / E61 (2004 - 2010)
BMW 5-Series E60 Sedan was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E61 wagon followed shortly there after. The E60/E61 5 series is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #1  
Old 03-27-2020, 10:18 AM
plus1111 plus1111 is offline
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2006 530xi AC clutch-pulley removal help, please.

After replacing the water pump last fall the bearing in the AC pulley began to grind. I suspect it's been grinding on and off for a while, but ...

I am trying to replace the pulley with the compressor on the car but I have run into a problem. The compressor shaft end, which is 7mm has been rounded off in a previous repair, I assume. The 7mm will not get a tight grip. 6mm is too small, 1/4" is too small. It's also on pretty tight - and I know which was to turn it.

I really do not want to remove the compressor because, besides discharging and recharging, it looks like the water pump mess has to come out. I've done enough of those to deeply avoid it, if possible.

Any suggestions on getting a good grip on that shaft while the thing is still on the car? I slipped some sheet steel between the 7mm and the shaft and pounded them together but still no grip. I'm at a loss right now.

Thanks folks.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #2  
Old 03-27-2020, 11:05 AM
twh twh is offline
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I have the same year and model. Mine is losing refrigerant at a slow rate - I have added some a couple times in the past 4 years. You might do well to just disassemble the system and change all the o-rings and schrader valves and fix your compressor (get a new one is better) and then take it to a shop to refill.
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  #3  
Old 03-27-2020, 11:50 AM
MarkCh MarkCh is offline
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Quote:
Originally Posted by plus1111 View Post
After replacing the water pump last fall the bearing in the AC pulley began to grind. I suspect it's been grinding on and off for a while, but ...

I am trying to replace the pulley with the compressor on the car but I have run into a problem. The compressor shaft end, which is 7mm has been rounded off in a previous repair, I assume. The 7mm will not get a tight grip. 6mm is too small, 1/4" is too small. It's also on pretty tight - and I know which was to turn it.

I really do not want to remove the compressor because, besides discharging and recharging, it looks like the water pump mess has to come out. I've done enough of those to deeply avoid it, if possible.

Any suggestions on getting a good grip on that shaft while the thing is still on the car? I slipped some sheet steel between the 7mm and the shaft and pounded them together but still no grip. I'm at a loss right now.

Thanks folks.
I created a how-to a while ago: https://www.bimmerfest.com/forums/showthread.php?t=1119121

Let add to answer your question; Turn the 7mm shaft clockwise, letting the still-installed-belt help hold the pulley still. It's in the above writeup.

@Banglenot has a thread too: https://www.bimmerfest.com/forums/sh....php?t=1366383

Use a socket type as shown here to grab the shaft: https://www.lowes.com/pd/Kobalt-Univ...-Set/999957955

Good luck and let us know how it works out.

Last edited by MarkCh; 03-27-2020 at 12:06 PM. Reason: added info
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  #4  
Old 03-27-2020, 12:32 PM
plus1111 plus1111 is offline
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MarkCh,
That multi-point socket set might get the job done. I've been thinking of trying to drive a 1/4" onto the shaft anyway ...

I will read the thread too. Thanks!

twh,
I have already decided that, if I have to remove the compressor, most likely a new one will go on. I really don't want to do the water pump again tho.

Thanks!
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Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #5  
Old 03-27-2020, 06:20 PM
plus1111 plus1111 is offline
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Well, no luck so far. /i am afraid the end of the compressor shaft no longer has much flatness to it. I am afraid to pound a smaller socket on with a lot of force for fear of breaking the internal thrust bearings but the pulley bearing may take most of the impact until it's loose.
Tomorrow is another go at it.
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I can't really remember the last time I took a car to a repair service.
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  #6  
Old 03-27-2020, 06:43 PM
PIXLFIX PIXLFIX is offline
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I replaced an AC pulley few days ago. The shaft was rounded so I couldnít use 7mm socket.
Mine is 528xi N52, but I guess 530xi is pretty much the same thing.
Copart BMW E60 528xi (part 2 of ?)
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  #7  
Old 03-27-2020, 08:10 PM
plus1111 plus1111 is offline
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Thanks PIXLFIX. I will study your video tomorrow. There is a lot of good information in it!
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I can't really remember the last time I took a car to a repair service.
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  #8  
Old 03-29-2020, 07:22 AM
jparnes1 jparnes1 is offline
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2006 530xi AC clutch-pulley removal help, please.

Try this bolt extractor socket. S designed for bolts with rounded hexes. Choose one that **almost** fits but slightly small. Bang it on the shaft with a mallet.

Eapele Impact Bolt Nut Removal Extractor Socket Tool Set (13pcs) https://www.amazon.com/dp/B07X5VGX69..._C6kGEb8CTY26Z

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  #9  
Old 03-29-2020, 08:25 AM
plus1111 plus1111 is offline
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Thanks!
I actually have a set of those but the thread id counter-clockwise. I got this item I shall try today:
https://www.amazon.com/Lisle-71200-S...5495504&sr=8-3
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #10  
Old 03-29-2020, 08:39 AM
jparnes1 jparnes1 is offline
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Quote:
Originally Posted by plus1111 View Post
Thanks!

I actually have a set of those but the thread id counter-clockwise. I got this item I shall try today:

https://www.amazon.com/Lisle-71200-S...5495504&sr=8-3


Thatís an awesome tool! Iím getting it just to have around.


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  #11  
Old 03-30-2020, 02:32 PM
plus1111 plus1111 is offline
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Hello to PIXLFIX.
Am I understanding that the took on your impact wrench is what removed the pulley front? I've located one for sale, it looks like the inside part holds the 7mm shaft and the outer part spins the pulley.
Nobody local has one so I will have to buy one. They are not cheap so I just want to be sure it's what I need.
Thanks!
__________________
Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #12  
Old 03-30-2020, 07:10 PM
PIXLFIX PIXLFIX is offline
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2006 530xi AC clutch-pulley removal help, please.

Quote:
Originally Posted by plus1111 View Post
Hello to PIXLFIX.
Am I understanding that the took on your impact wrench is what removed the pulley front? I've located one for sale, it looks like the inside part holds the 7mm shaft and the outer part spins the pulley.
Nobody local has one so I will have to buy one. They are not cheap so I just want to be sure it's what I need.
Thanks!


In my case nothing was holding the shaft. It was free spinning. But thatís not a big problem when you use an impact gun. It unscrew the front even without holding the shaft.
That tool came along with a pulley I purchased. Approximate $95 for that set.

Last edited by PIXLFIX; 03-30-2020 at 07:13 PM.
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Old 03-30-2020, 07:31 PM
plus1111 plus1111 is offline
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That's good news. I already bought the pulley and the price for the tool brings my investment to about the same $$.
Need an impact wrench tho - maybe I can find a really short one.
Thanks!
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Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #14  
Old 03-30-2020, 08:24 PM
PIXLFIX PIXLFIX is offline
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Quote:
Originally Posted by plus1111 View Post
That's good news. I already bought the pulley and the price for the tool brings my investment to about the same $$.

Need an impact wrench tho - maybe I can find a really short one.

Thanks!


Make sure to have belt off the pulley
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  #15  
Old 03-30-2020, 08:27 PM
plus1111 plus1111 is offline
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Actually, the belt has been off for a month or two. I put a shorter bypass belt on so I could use the car.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #16  
Old 04-05-2020, 01:02 PM
plus1111 plus1111 is offline
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Well, the pulley came of with the cool tool and an impact wrench. My fat tinger job managed to rip the spring clip groove right off the front of the compressor. New compressor time.

Do I need to remove the water pump to replace the compressor?

Grrr.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #17  
Old 04-06-2020, 06:44 AM
MarkCh MarkCh is offline
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Quote:
Originally Posted by plus1111 View Post
Well, the pulley came of with the cool tool and an impact wrench. My fat tinger job managed to rip the spring clip groove right off the front of the compressor. New compressor time.

Do I need to remove the water pump to replace the compressor?

Grrr.
So you actually broke the aluminum lip off the compressor body where the serrated 'C' clip holds the pulley (actually the bearing in the pulley) onto the compressor?? How did you manage that just by unscrewing the *pulley insert off the shaft? Did you use a puller on the pulley before removing that large serrated 'C' clip?

*Pulley insert is the aluminum and black part that screws onto the shaft, it has six raised points where the rubber cushions attach to, it is not the actual pulley.

As in my 'how to' link I provided above; A little WD40 spray on the exposed 7mm shaft, and leave the belt on the A/C pulley (to help hold the pulley still). Use your left hand to hold the pulley with belt still on, then a hard initial clockwise turn of the free-wheeling shaft with the 7mm socket & 1/4 ratchet with your right hand will break it loose. Once it breaks free, the shaft will turn fairly easy, just a shock is needed to break the aluminum/pot metal from the steel threaded shaft. Once it starts to turn, then remove the belt, and spin the pulley counter clockwise while holding the shaft still with the 7mm socket and 1/4" ratchet. As you spin the pulley counter clockwise, the pulley insert with rubber cushes will thread itself away from the pulley, revealing the serrated 'C' clip. At this time, the pulley will still be in place, it is not removable until the serrated 'C' clip is first removed.
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Old 04-06-2020, 07:52 AM
plus1111 plus1111 is offline
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I do not think I am the first one to work on this compressor. The 7mm shaft was almost completely rounded before I got to it. A 7mm wrench barely gripped at all. I tried several different things to grip the shaft and all failed. I bought the tool PIXLFIX used in his video and it worked like a charm. The snap ring came off with no issue. The pulley didn't really require a lot of coaxing to come off, either.

I think it was damaged in a previous repair because I didn't lean on any of it enough to make a fresh break. The pulley came off fairly straight, no serious twisting.

Still, I will have to replace the compressor to do it right. I am quite depressed at the moment.
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Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #19  
Old 04-06-2020, 09:45 AM
MarkCh MarkCh is offline
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Quote:
Originally Posted by plus1111 View Post
I do not think I am the first one to work on this compressor. The 7mm shaft was almost completely rounded before I got to it. A 7mm wrench barely gripped at all. I tried several different things to grip the shaft and all failed. I bought the tool PIXLFIX used in his video and it worked like a charm. The snap ring came off with no issue. The pulley didn't really require a lot of coaxing to come off, either.

I think it was damaged in a previous repair because I didn't lean on any of it enough to make a fresh break. The pulley came off fairly straight, no serious twisting.

Still, I will have to replace the compressor to do it right. I am quite depressed at the moment.
To clarify, the lip of the compressor body (where the serrated snap ring is) has broke off? If it's just the outer lip (where the snap ring would come off), AND the surface on the compressor where the bearing slides on is still OK, then perhaps one option would be to use a locking compound such as 'Loctite 37424 640 High Strength Sleeve Retainer' in place of the 'C' clip. Additionally, the pulley insert (with rubber bumpers) will be threaded onto the 7mm shaft and 'should' not allow the pulley to come off the compressor if in the event that the locking compound let go. It would be a lot easier than replacing the compressor.

Let me add, that I am not a mechanic.
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